Ceramic porous stone KERAKAM 38 SuperThermo® is produced at one of the leading Russian enterprises in the construction industry, ZAO Samara Ceramic Materials Plant. This company is distinguished from other manufacturers by a large assortment of products containing 17 items, which makes it possible to build houses with complex architecture entirely from a homogeneous material.
The Kirill company has been successfully selling and supplying KERAKAM warm ceramics for a long time both to private construction projects and to numerous townhouse villages and high-rise buildings in the Moscow region. At the exhibition "Beautiful Houses 2013", Kirill presented an exposition with a demonstration of wall masonry from blocks of warm ceramics of different sizes in the villages of Marseille, Bristol, Cambridge.
KERAKAM 38 SuperThermo® (260х380х219) is a modern high-tech product that fully meets modern thermal engineering standards and at the same time has a rational thickness of 38 cm. KERAKAM 38 SuperThermo® stone has sufficient strength (92 kgf / cm2) for the construction of houses with load-bearing walls up to 3 floors. One stone can withstand an evenly distributed load of more than 90 tons.
Environmental friendliness
KERAKAM 38 SuperThermo® is made from environmentally friendly natural materials: clay and sawdust, which burn out during firing. As a result, the ceramic stone has a capillary structure that allows the wall to "breathe". The wall, built of ceramic stones KERAKAM 38 SuperThermo® from the Kirill company, remains dry at any time of the year.
Thermal insulation properties
Thermal properties of large-format ceramics are formed due to three main factors: the percentage of voidness, the density of the ceramic shard (degree of porosity) and the structure of the voids. The diamond-shaped voids of the large-format stone KERAKAM 38 SuperThermo® provide the best thermal performance.
The high voidness of the porous stone KERAKAM 38 SuperThermo® (54.1%) in combination with the microporous structure of the fired shard determines the low thermal conductivity of this material - 0.110 W / (m ° C).
KERAKAM 38 SuperThermo® has low thermal conductivity, but unlike cellular concrete, it has a fairly high density (730 kg / m3), which allows walls built from this material to acquire the properties of high thermal inertness. Thanks to this, the energy consumption costs for maintaining a comfortable temperature in the living quarters of the house are significantly reduced both in winter and in summer.
Thermal inertia
For regions with an estimated July temperature above +21 ° C, not only winter thermal protection (through resistance to heat transfer), but also summer (through thermal inertia) is standardized. However, taking thermal inertia into account is useful not only in the Stavropol Territory or in the Krasnodar Territory, but also in more temperate latitudes. Well-organized summer thermal protection allows you to do without air conditioning in your home.
The thermal inertia of a structure characterizes the rate at which the temperature front passes through it. The higher the thermal inertia of the structure, the longer it takes for the temperature effect exerted on the outside to appear on its inner surface. This property is most useful in a sharply continental climate, when the difference between day and night temperatures is very different. In houses, the walls of which have high thermal inertia, during the period of fluctuations in daily temperatures around 18 … 23 ° C, close to the physiological optimum, energy is significantly saved for the operation of systems for maintaining a given air temperature in the premises, since daily temperature fluctuations fade in the thickness of the wall, not conducting the night cold or daytime heat into the room.
Another important parameter for passive summer heat protection is the heat storage capacity of house structures. Specific heat does not depend linearly on thermal inertia and affects comfort in a different way. Massive heat-absorbing structures in summer can cool the air in a room, and in winter, in case of interruptions in the operation of heating systems, for some time maintain a comfortable microclimate, releasing stored heat into the room. Walls made of KERAKAM 38 SuperThermo® ceramic blocks from Kirill have significant heat storage properties and thermal inertia. In such houses, even without the use of special heating and cooling systems for the outside air, comfortable conditions will be maintained in the summer heat, interspersed with cold nights: at night the room will not cool down noticeably, and during the day it will remain cool.
Simplicity of masonry
KERAKAM 38 SuperThermo® replaces 11 regular size bricks in the masonry. At the same time, large-format stone, due to its high voidness, remains light in weight (15.4 kg) and simple in masonry technology. The presence of a special tongue-and-groove structure of the joint of the side surfaces of the stone significantly simplifies the masonry technology, reduces the requirements for the professional level of masons and, in total, reduces the construction time by 3-5 times.
The size of the KERAKAM 38 SuperThermo® stone is based on the Russian modular building materials system, so it can be easily tied to a brick with a height of 65 mm. (thickness according to GOST 530-2012), i.e. every three facing bricks with a 12 mm joint. form the height of the block itself 219 mm.
Durability
The absence of the need to use effective insulation, allows the construction of wall structures with a thickness (no more than 50.0 cm) in one KERAKAM 38 SuperThermo® stone with a facing of ceramic bricks. Such walls are most resistant to negative environmental influences: temperature extremes in combination with alternating moistening of the masonry and wind loads. They also have high durability (more than 100 years) and economy, if we take into account not only construction costs, but also operating and repair costs.
Profitability
Despite the large format, KERAKAM 38 SuperThermo® (11.1 NF) is 38% lighter than hollow bricks of the same volume and 56% lighter than solid bricks, which significantly reduces the load on the foundation and, consequently, the costs of its production.
The large format of KERAKAM 38 SuperThermo® allows you to significantly speed up the masonry - if a bricklayer lays an average of 1-1.5 m of ordinary brick per shift3 masonry, then from large-format stone KERAKAM 38 SuperThermo® in the same time up to 8 m3, which also leads to a decrease in the cost of masonry.
The joint of vertical joints in a groove and a tongue in large-format KERAKAM 38 SuperThermo® blocks does not require mortar, therefore, mortar consumption for masonry is reduced by about 84% compared to conventional single bricks.
The value of the heat transfer resistance of the wall structure with a thickness of not more than 50.0 cm. Made of ceramic stones KERAKAM 38 SuperThermo® including facing brick is 3.51 m2 • ° С / W (operating conditions - B), which is 12.1% higher than the permissible value resistance to heat transfer of walls for residential premises for Moscow (3.13 m² • ° С / W). These indicators are exceptional for a homogeneous ceramic wall and can significantly reduce heating costs and energy consumption compared to similar materials on the market of the Russian Federation.
The use of KERAKAM 38 SuperThermo® stone is the most rational for the construction of external walls of the house in comparison with all available similar large-format blocks. For example, replacing a large 51 cm thick stone with KERAKAM 38 SuperThermo® allows you to get an additional building area of 0.13 m2 from each running meter of the wall, i.e. 5.2 m2 from every 100 m2 previously planned area.
Heat transfer resistance requirements
Thermal characteristics of external enclosing structures are assigned based on sanitary and hygienic and comfortable conditions, as well as on energy saving conditions. The design of thermal protection of residential and public buildings with year-round operation should be introduced on the basis of energy saving conditions. For Moscow the reduced heat transfer resistance of the outer walls is Rreg = 3.13 m² • ° С / W.
To determine the required wall thickness, the heat transfer resistance of the masonry, insulation and facing layers is calculated. According to the results of the calculation, the required thickness of the masonry is assigned, which ensures a comfortable stay. The design heat transfer resistance of masonry made of KERAKAM 38 SuperThermo® stones with facade brick cladding (102 mm) is determined by the formula:
Ro = 1 / αv + R1 + R2 + R3 + 1 / αn, αw = 8.7 W / (m² • ° С) is the heat transfer coefficient of the inner surface of the enclosing structures;
αн = 23 W / (m² • ° С) - heat transfer coefficient (for winter conditions) of the outer surface of the enclosing structure;
R1 = δ1 / λ1 - thermal resistance of DAAS BAKSTEEN facing brick based on cement-sand mortar, m² • ° С / W;
R2 = δ2 / λ2 - thermal resistance of KERAKAM 38 SuperThermo® stone based on cement-sand mortar, m² • ° С / W;
R3 = δ1 / λ1 - thermal resistance of the cement-sand mortar applied indoors, m² • ° С / W.
Ro = 1 / 8.7 + 0.102 / 0.53 + 0.380 / 0.121 + 0.015 / 0.76 + 1/23 = 3.51 m2 • ° С / W
It follows from the calculations that even with a wall thickness of 38 cm made of KERAKAM 38 SuperThermo® stone (0.380 / 0.121 = 3.14 m² • ° C / W) it meets the requirements for the walls of residential buildings, based on living comfort and energy saving conditions.
Manufacturing jobs
When constructing buildings from ceramic porous stone KERAKAM 38 SuperThermo®, the requirements of SNiP 3.03.01-87 "Bearing and Fencing Structures" (Section 7 "Stone Structures") and the manufacturer's recommendations for the design, erection of walls and partitions of buildings should be followed. Before laying, stones must be cleaned of possible dirt and visually checked for integrity. Stones that have mechanical damage (chipped edges, corners) are allowed to be used when laying gable walls or internal walls.
Start of masonry
It is recommended to start the laying of ceramic stones from the corners of the building and lead in complete rows along the entire perimeter. In this case, it is necessary to constantly monitor the mutual perpendicularity of the vertical and horizontal joints of the masonry, as well as the verticality of the walls with the help of tools.
Groove-comb
Before applying the solution, it is recommended to moisten the surface of the stones with water for better adhesion. After the solution is prepared, it is unloaded into a container for temporary storage, then distributed along the length of the wall (by 2 ÷ 3 stones), leveling the bed. The stone is lowered onto the mortar from above (groove into the ridge), avoiding horizontal movement of more than 5 mm. It is allowed to correct the position of stones by swinging or tamping with a rubber mallet hammer. The excess solution squeezed out at the same time is removed immediately, preventing their seizure.
When erecting walls, a single-row system for tying vertical seams should be used. This rule is ensured by using KERAKAM 38 SuperThermo® + filling stones or cutting KERAKAM 38 SuperThermo® standard stone using an electric alligator saw.
Masonry mortar
For laying large stones, you can use ordinary masonry mortar and even a simple cement-sand mixture. However, we recommend using a special warm solution LM 21-P. Masonry on a warm mortar allows you to reduce the thermal conductivity of the masonry and reduce heat loss through the wall by 7-12%. The average thickness of the horizontal joints should be 12 mm. The side surfaces of large-format ceramic stone are alternating grooves and ridges. This design allows you to get a reliable sealed joint during masonry, which does not require filling with mortar. Special attention should be paid to horizontal joints, since the strength and bearing capacity of the entire masonry largely depends on their quality.
Reinforcement
In general, KERAKAM 38 SuperThermo® large stone masonry is not reinforced. If the reinforcement is assigned by the project, mesh reinforcement of horizontal seams using smooth round steel of classes A-I and Bp-I with a diameter of 3 ÷ 4 mm can be used. The mesh sizes of the reinforcing meshes should be from 30 × 30 to 120 × 120 mm. Reinforcement meshes should be laid at least every three rows of ceramic stone masonry. It is not advisable to reinforce the masonry if its bearing capacity is used by less than 50%.
Channels and mines
It is recommended to arrange vertical ducts and cable shafts in the thickness of the masonry provided by the project using special profile ceramic stones KERAKAM U. Channels and niches arranged in the thickness of the existing masonry should not reduce the bearing capacity of the walls and should not pass along the lintels or other parts of the structure built into the wall. Unlike vertical channels, horizontal and diagonal channels are undesirable. If they cannot be avoided, then they should be at a distance of 1/8 of the height of the room from the lower or upper surface of the floor structures.
Supporting floor slabs
The bearing depth of reinforced concrete floor slabs and pavements must be at least 120 mm. It is recommended to reinforce the supporting mortar joint with a mesh of 3-5 mm rods with a mesh size of 50x50-75x75 mm.
For large loads, to distribute them over a large area, you should use cushion rows of solid bricks or monolithic reinforced concrete belts and cushions.
Application of dowels
For fixing in a wall made of porous ceramic stones, as a rule, plastic dowels with a spacer area along the entire length are used. The fastening that passes through the multiple walls creates a sufficient fastening force. For example, the use of a dowel: MU with a diameter of 8 mm and a length of 50 mm + a screw with a diameter of 5 mm and a length of 10 mm - provides a pullout force range from 64 to 151 kg. The use of an SX nylon dowel with a diameter of 12 mm and a length of 60 mm + a countersunk screw Rz with a diameter of 8 mm and a length of 85 mm increases the pull-out force range from 360 to 423 kg.
The holding capacity of the dowels mainly depends on their size (diameter and length). For heavy loads, such as a hinged ventilated façade, anchoring to the wall should be done with a so-called chemical dowel (anchor).
Cladding
When laying walls with a facing layer of brick, it is recommended to ensure the offset of the vertical joints of the outer layer relative to the inner layer of stones. Fastening of cladding to walls made of large-format ceramic stones is carried out using flexible metal or plastic ties, which are installed through 6 rows of facing bricks in buildings up to 5 floors and after 3 rows - up to 9 floors with a step of 750 mm in a horizontal direction in a checkerboard pattern.
It is also recommended to use flexible basalt-plastic ties with sand anchors at both ends of the "Galen" type D = 6mm, L = 250mm.
Your house or high-rise building is a serious construction task. But with the Samara Kerakam SuperThermo from the Kirill company, you will always quickly cope with it, reliably providing decades of a happy life.
Warm ceramics KERAKAM 38 SuperThermo® for warmth in your home!
Representative office of the Kirill company at Archi.ru.
